Artificial resin and method of preparation



Patented a... re, teas;

nniran snares cantnron ELLIS, or MONTGLAIR, new master.

ARTIFICIAL RESIN AND METHOD OF PREPARATION; I

No Drawing.

of Montclair, in the county of Essex and t3 State of New Jersey, have invented certain new and useful Improvements in Artificial Resins and Methods of Preparation, of which .the following is a specification.

This invention relates to resinous material an obtained by the reaction between phenols or phenoloid bodies and butyl aldehyde with or without the presence of furfural.

Aldehydes possess different powers of resinification with phenolic substances and 3155 require different catalysts for their preparation. Hence" it'is impossible to predict definitely the results to be obtained by using an particular combination of phenols and aldhhydes. Some phenolic substances will an notresinify With aldehydes but tend rather to form oils or cystalline substances. In the present invention it is an object to prepare a resin from butyl aldehyde and ordinary phenol, cresols o-r phenoloid bodies. Butyl 2% aldehyde does not combine with phenol readily in the resence of alkaline catalysts such for examp e as potassium carbonate but will form ,a resin in the presence of acids, more particularly strong mineral acids such as hydrochloric acid. The rotracted heating of phenol and butyl alde yde in molecular proportions in the presence of a small amount of hydrochloric acid yields a soft resin. I

For example 47 parts by weight of phenol and 36parts of butyl aldehyde with the addition of one part of concentrated hydrochloric acid were heated under a reflux condenser in an oil bath for-4 hours. The oil 40 bath was maintained at 150 C. On allowing the reaction mixture to cool approxi mately 5 parts of water separated. A brown soft highly viscous resinous substance was obtained which on further heating increased in consistency and became harder.

' By decreasing or increasing the proportion of butyl aldehyde products of different quality are obtained.

Application filed December 26, 1922.. Serial No. 609,135.

In another case 1 molecular proportion of phenol to mol. of butyl aldehyde was likewise heated in thepresenoe of a hydrochloric acld catalyst. When the reaction had progressed to a sufficient degree 1} mol. of furfural was added and suflicient potassium carbonate to render the mixture alkaline. The heating was continued at about 150 until the turfural had combined forming a black resinous complex.

Of course the catalyst may be removed if desired at the close of the operation by suitable washing treatment, by neutralization or in any other manner.

Formaldehyde, paraform, heXamethylenetetramine and various other similar substances may be incorporated with the resin, likewise fillers such as asbestos or mineral powders, Wood flour and the like. Such compositions ma be used for molding purposes. Solutions oi the resin in appropriate solvents may be employed as varnishes or for cements or for impregnating paper, wood pulp and the like to produce plastic products, sheet material etc. The molding operation may be carried out under heat and pressure or the process of cold molding may be employed in some cases.

.What I claim is r- 1. A resinous composition prepared from butyl aldehyde and a phenolic body.

2. A resinous substance prepared from butyl aldehyde, furfuralv and a phenolic body.

3. The process of making a resin which comprises heating phenol and butyl aldehyde with an acid catalyst. v

4. The process of making'a resin which comprises heating phenol and butyl aldehyde with an acid catalyst and reacting on the product with furfural in the presence of a alkaline catalyst.

5. A resinous substance comprising a butyl aldehyde, :v henol resin incorporated with hexamethy enetetramine and filling material.

CARLETON ELLIS. 

